Implantable paddle lead comprising compressive longitudinal members for supporting electrodes and method of fabrication

Abstract

In one embodiment, a paddle-style lead for implantation in the epidural space, the paddle-style lead comprising: a paddle structure that comprises a frame of rigid material, the frame comprising first, second, and third longitudinal members, a distal linking portion that is mechanically coupled to the first, second, and third longitudinal members, and a proximal linking portion that is mechanically coupled to the first, second, and third longitudinal members; wherein a respective plurality of electrodes are provided for each of the first, second, and third longitudinal members, each plurality of electrodes being electrically coupled to conductors of a lead body; wherein the distal and proximal linking portions are adapted to permit compression of the first and third longitudinal members toward each other and to permit the second longitudinal member to move out of plane relative to the first and third longitudinal members when a compressive force is applied to the paddle.

1. A paddle-style lead for implantation in the epidural space through an insertion tool, the paddle-style lead comprising:
 a lead body; 
 a plurality of conductors extending from a proximal portion of the lead body to a distal portion of the lead body; 
 a plurality of terminals that are electrically coupled to the plurality of conductors; and 
 a paddle structure that comprises a frame of rigid material, the frame comprising first, second, and third longitudinal members in a planar configuration, a distal linking portion that is mechanically coupled to the first, second, and third longitudinal members, and a proximal linking portion that is mechanically coupled to the first, second, and third longitudinal members; 
 wherein a respective plurality of electrodes are provided for each of the first, second, and third longitudinal members, each plurality of electrodes being electrically coupled to conductors of the plurality of conductors; 
 wherein the distal and proximal linking portions are adapted to permit compression of the first and third longitudinal members toward each other and to permit the second longitudinal member to move out of plane relative to the first and third longitudinal members when a compressive force is applied to the paddle. 
 
     
     
       2. The paddle-style lead of  claim 1  wherein the distal and proximal linking portions provide a spring-force to restore the first, second, and third longitudinal members to the planar configuration after removal of compressive forces upon the paddle. 
     
     
       3. The paddle-style lead of  claim 1  wherein the second longitudinal member comprises a plurality of columns of electrodes along a length of the second longitudinal member. 
     
     
       4. The paddle-style lead of  claim 1  wherein the first, second, and third longitudinal members are fabricated using a rigid polymer selected from the group consisting of PEEK, PEKK, and LCP. 
     
     
       5. The paddle-style lead of  claim 1  wherein the plurality of electrodes of the first, second, and third longitudinal members are deposited on rigid insulative material of the first, second, and third longitudinal members. 
     
     
       6. The paddle-style lead of  claim 1  wherein the plurality of electrodes of the first, second, and third longitudinal members are disposed on an intermediate polymer later that is laminated to a thicker substrate layer. 
     
     
       7. The paddle-style lead of  claim 1  wherein electrical connectors are embedded within the first, second, and third longitudinal members and the electrical connectors are electrically coupled to the plurality of electrodes through vias in insulative material. 
     
     
       8. The paddle-style lead of  claim 1  wherein the plurality of electrodes of the first, second, and third longitudinal members are provided on one or more flex-circuits that are laminated to rigid insulative material of the first, second, and third longitudinal members. 
     
     
       9. The paddle-style lead of  claim 1  wherein the distal linking portion provides a spring force to the paddle to bias the first, second, and third longitudinal members in a planar configuration. 
     
     
       10. The paddle-style lead of  claim 1  wherein the proximal linking portion provides a spring force to the paddle to bias the first, second, and third longitudinal members in a planar configuration. 
     
     
       11. A method of fabricating a paddle-style lead for implantation in the epidural space through an insertion tool, the method comprising:
 providing a lead body with a plurality of conductors extending from a proximal portion of the lead body to a distal portion of the lead body; 
 forming a paddle structure comprising a frame of rigid material, the frame comprising first, second, and third longitudinal members in a planar configuration, a distal linking portion that is mechanically coupled to the first, second, and third longitudinal members, and a proximal linking portion that is mechanically coupled to the first, second, and third longitudinal members, wherein the distal and proximal linking portions are adapted to permit compression of the first and third longitudinal members toward each other and to permit the second longitudinal member to move out of plane relative to the first and third longitudinal members when a compressive force is applied to the paddle; 
 providing a respective plurality of electrodes for each of the first, second, and third longitudinal members; and 
 electrically coupling each plurality of electrodes to conductors of the plurality of conductors. 
 
     
     
       12. The method of  claim 11  wherein the distal and proximal linking portions provide a spring-force to restore the first, second, and third longitudinal members to the planar configuration after removal of compressive forces upon the paddle. 
     
     
       13. The method of  claim 11  wherein the second longitudinal member comprises a plurality of columns of electrodes along a length of the second longitudinal member. 
     
     
       14. The method of  claim 11  wherein the first, second, and third longitudinal members are fabricated using a rigid polymer selected from the group consisting of PEEK, PEKK, and LCP. 
     
     
       15. The method of  claim 11  wherein the plurality of electrodes of the first, second, and third longitudinal members are deposited on rigid insulative material of the first, second, and third longitudinal members. 
     
     
       16. The method of  claim 11  wherein the plurality of electrodes of the first, second, and third longitudinal members are disposed on an intermediate polymer later that is laminated to a thicker substrate layer. 
     
     
       17. The method of  claim 11  wherein electrical connectors are embedded within the first, second, and third longitudinal members and the electrical connectors are electrically coupled to the plurality of electrodes through vias in insulative material. 
     
     
       18. The method of  claim 11  wherein the plurality of electrodes of the first, second, and third longitudinal members are provided on one or more flex-circuits that are laminated to rigid insulative material of the first, second, and third longitudinal members. 
     
     
       19. The method of  claim 11  wherein the distal linking portion provides a spring force to the paddle to bias the first, second, and third longitudinal members in a planar configuration. 
     
     
       20. The method of  claim 11  wherein the proximal linking portion provides a spring force to the paddle to bias the first, second, and third longitudinal members in a planar configuration.